Effectiveness of application of new consumables in welding and surfacing of copper and its alloys (Review)

Abstract

Results of investigations on development of high-efficient electrode and filler materials for welding and surfacing of copper and alloys on its base are considered. It is shown that increased requirements to quality of welded joints and deposited metal can be satisfied, primarily due to development of reliable welding consumables: electrode and filler wires, fluxes (fused and activating flux-pastes), as well as special coated electrodes. Arc welding and surfacing processes improved on their base provide the required level of thermophysical properties of welded joints, high strength and tightness of welds, reliable service durability in friction assemblies and corrosion media, etc. Effectiveness of new welding consumables is confirmed by their practical application in manufacture of welded crucible moulds of electrometallurgical furnaces, welding busbars, electrode holders, enlargement of hot-rolled coils for their further rolling, making various bimetal items by surfacing, etc. 10 Ref., 5 Tables. K e y w o r d s : arc welding and surfacing, copper and its alloys, electrode and filler wires, fluxes, coated electrodes, welded joints, thermophysical properties, quality

Hardfacing of Copper

“…The surfacing of steel with copper and copper alloys is not accompanied by any specific problems. Many researchers state that, in the above-named case, the simplest and, at the same time, the most effective solution should involve gas-shielded metal arc surfacing or submerged arc surfacing [9,20]. The primary disadvantage of arc surfacing is significant penetration depth, potentially leading to the excessive mixing of the non-ferrous metal with steel, resulting in the reduction of operational properties of the surfaced metal as well as the formation of cracks and gas pores in the deposited layer [20].…”

“…Many researchers state that, in the above-named case, the simplest and, at the same time, the most effective solution should involve gas-shielded metal arc surfacing or submerged arc surfacing [9,20]. The primary disadvantage of arc surfacing is significant penetration depth, potentially leading to the excessive mixing of the non-ferrous metal with steel, resulting in the reduction of operational properties of the surfaced metal as well as the formation of cracks and gas pores in the deposited layer [20]. However, in spite of the fact that arc welding is characterised by significant penetration depth, the submerged arc welding method is sometimes used for the welding of copper with copper or copper with steel having a thickness restricted within the range of 5 mm to 40 mm [9,13,21].…”

Effectiveness of application of new consumables in welding and surfacing of copper and its alloys (Review)

“…The same principle of additional alloying of weld metal with chromium and titanium was the basis for development of special filler flux-cored wire PP-BrKhT12-2, designed for plasma-arc welding of copper and chromium copper. This flux-cored filler wire is used with success in manufacture of welded moulds of crucibles of electrometallurgical furnaces in OJSC «Sibelektroterm» (Novosibirsk, RF) [2,3].…”

“…In view of certain complexity of manufacturing these wires (melting in vacuum furnaces, rod pressing, rolling, annealing of billets and drawing), a more accessible filler material for TIG process is flux-cored wire of PP-AN-M1 grade, developed by PWI [3]. Doping flux-cored wire composition with effective deoxidizers ensures the required quality and thermophysical properties of welded joints in helium-arc welding of thick-walled elements of various electrical engineering products (motors, busbars, etc.…”

“…Test batches of developed electrodes are made at the PWI Science and Technology Complex. As shown by investigations, the most effective measure to prevent weld porosity in copper welding turned out to be application of low-silicon manganese flux manufactured by air-stream granulation with higher oxidation degree [3]. New flux of AN-M13 grade ensures producing vacuum-tight welds in manufacture of crucible moulds for VAM and ESM furnaces.…”